WO2016143730A1 - Réacteur - Google Patents

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Publication number
WO2016143730A1
WO2016143730A1 PCT/JP2016/056936 JP2016056936W WO2016143730A1 WO 2016143730 A1 WO2016143730 A1 WO 2016143730A1 JP 2016056936 W JP2016056936 W JP 2016056936W WO 2016143730 A1 WO2016143730 A1 WO 2016143730A1
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WO
WIPO (PCT)
Prior art keywords
core
winding
core pieces
pair
resin
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Application number
PCT/JP2016/056936
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English (en)
Japanese (ja)
Inventor
誠二 舌間
雅幸 加藤
Original Assignee
株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2016143730A1 publication Critical patent/WO2016143730A1/fr

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00

Definitions

  • the present invention relates to a reactor used for a vehicle-mounted DC-DC converter or a power converter component mounted on a vehicle such as a hybrid vehicle.
  • Patent Document 1 discloses a reactor used for a circuit component of an in-vehicle converter.
  • Patent Document 1 discloses a mold type reactor in which most of the outer periphery of the reactor is molded with resin.
  • the reactor includes a bobbin (intervening member) interposed between the coil and the magnetic core, and the intervening member is provided with a guide portion that secures a gap (interval) between adjacent partial cores (core pieces). It has been.
  • Patent Document 1 describes that the space between the core pieces is filled with mold resin.
  • the present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a reactor in which core pieces can be easily held at predetermined positions and excellent in productivity.
  • the reactor which concerns on 1 aspect of this invention combines the coil which has a winding part, the gap material interposed between several core pieces and each core piece, and has the magnetic part which has a part arrange
  • a core a cylindrical interposition member interposed between the inner surface of the winding portion and the magnetic core, and sandwiching the plurality of core pieces at a predetermined position; and a resin for integrating the coil and the magnetic core
  • the interposition member is constituted by a pair of divided interposition members that are divided in the circumferential direction and sandwich the plurality of core pieces, and each core piece is positioned by securing a space between the plurality of core pieces.
  • a guide part is provided.
  • the reactor is easy to hold the core pieces in place and has excellent productivity.
  • FIG. 1 is a schematic exploded perspective view of a reactor according to a first embodiment. It is a perspective view which shows the interposed member with which the reactor which concerns on Embodiment 1 is provided.
  • FIG. 4 is a (IV)-(IV) cross-sectional view of the reactor of FIG. 1. It is a perspective view which shows the interposition member with which the reactor which concerns on Embodiment 2 is provided.
  • the reactor which concerns on embodiment of this invention combines the coil which has a winding part, several core pieces, and the gap material interposed between each core piece, and the part arrange
  • the interposition member is constituted by a pair of divided interposition members that are divided in the circumferential direction and sandwich the plurality of core pieces, and each core piece is positioned by securing a space between the plurality of core pieces.
  • a guide part is provided.
  • the reactor includes, for example, a plurality of inner core pieces arranged in the winding portion among the plurality of core pieces in the interposed member, and the inner core piece and the interposed member arranged in the winding portion.
  • the assembled core is assembled with the outer core piece placed outside the winding part of the magnetic core in the assembly.
  • the resin mold part is not solidified by placing the assembly in the mold. Can be manufactured by the procedure of filling and solidifying.
  • the above reactor is arranged along the guide portion when arranging the plurality of core pieces on the interposition member, so that the interval between the adjacent core pieces is secured and the relative positioning of each core piece is accurately performed. it can.
  • the interposition member is composed of a pair of split interposition members that are divided in the circumferential direction and sandwich the plural core pieces, the plural interposition members are placed on one split interposition member, and the other split interposition member is Since the plurality of core pieces can be sandwiched simply by covering, it is easy to hold the core pieces at predetermined positions. Moreover, in the production of the assembly in the manufacturing process of the reactor, the plurality of core pieces sandwiched between the pair of split interposed members can be handled in a state in which the position of each core piece is maintained, so that the workability is excellent.
  • the interposition member includes a flow path that allows unsolidified constituent resin of the resin mold portion to flow between the plurality of core pieces when the resin mold portion is molded.
  • the gap material may be formed of a resin component of the resin mold part.
  • the unsolidified constituent resin flows between a plurality of core pieces.
  • a gap material having a width corresponding to the interval between them is formed.
  • the resin can surely flow into between the core pieces along the flow path.
  • a gap material between the core pieces can be formed, and the outer periphery of the coil and the outer periphery of each core piece (magnetic core) can be covered with resin, so that the coil and the magnetic core are integrated. be able to. Therefore, for example, the core piece and the gap material can be fixed in advance with an adhesive or the like, and the work of individually molding the core piece and the coil with resin can be simplified, and the reactor productivity is excellent. .
  • the flow path is an end along the axial direction of the winding portion of the interposed member on at least one of the inner peripheral surface or the outer peripheral surface of the interposed member.
  • the form provided with the groove part formed toward the inward from the part is mentioned.
  • the non-solidified resin of the resin mold part easily flows into between the core pieces.
  • the unsolidified component resin of the resin mold part flows into between the interposed member and the core piece, or between the interposed member and the coil, the contact between the core piece (magnetic core) and the resin mold part is ensured.
  • the area and the contact area between the coil and the resin mold portion can be increased. Therefore, it is easy to improve the bonding strength between the coil and the magnetic core via the resin mold part.
  • the reactor including the flow path
  • a form in which the flow path includes a through-hole penetrating from the outer surface to the inner surface of the interposition member can be given.
  • the non-solidified resin of the resin mold part easily flows into between the core pieces.
  • the resin mold part is fitted inside and outside of the interposed member through the through hole, the bonding strength between the core piece (magnetic core) and the resin mold part and the bonding strength between the coil and the resin mold part are increased. Easy to improve.
  • the coil includes a pair of winding portions arranged side by side, and the interposed member includes the winding of the plurality of core pieces for each of the pair of winding portions.
  • positioned in a rotation part integrally is mentioned.
  • the coil includes a pair of winding parts arranged side by side, and the magnetic core includes an outer core base disposed outside the winding part, and the outer core base.
  • a pair of projecting portions that protrude and are respectively disposed in the winding portion, and a U-shaped outer core piece formed integrally with the projecting portion of the outer core piece, the winding portion of the interposition member The form inserted from the edge part along the axial direction of this is mentioned.
  • the relative positioning of the core pieces is further increased by inserting the protruding portions of the U-shaped outer core pieces from both ends of the interposition member. Can be accurate.
  • the assembly can be handled as an integrated object while maintaining predetermined positions (positions of the core pieces, positions of the core pieces (magnetic core) and the coil) of the constituent members of the reactor, the workability is excellent.
  • Embodiment 1 A reactor 1 according to Embodiment 1 will be described with reference to FIGS. 1 to 3.
  • the reactor 1 of Embodiment 1 is arrange
  • the magnetic core 3 includes a plurality of inner core pieces 31m,... That are arranged entirely inside the winding portions 2a, 2b, and outer core pieces 32m, 32m having portions arranged outside the winding portions 2a, 2b. And gap members 31g,...
  • the interposed member 5 includes a pair of divided interposed members 5A and 5B divided in the circumferential direction, and the winding portion of the magnetic core 3 is formed by the pair of divided interposed members 5A and 5B.
  • the interposed member 5 includes a guide portion 52 that secures a space between the plurality of core pieces 31m, ..., 32m, 32m and positions the core pieces 31m, ..., 32m, 32m. I will.
  • the reactor 1 according to the first embodiment is characterized in that it includes a flow path 53 that allows the unsolidified resin of the resin mold portion 6 to flow into the spaces between the core pieces 31m, ..., 32m, 32m.
  • a flow path 53 that allows the unsolidified resin of the resin mold portion 6 to flow into the spaces between the core pieces 31m, ..., 32m, 32m.
  • the coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding a single continuous winding 2w, and both winding portions 2a, A connecting portion 2r for connecting 2b.
  • Each winding part 2a, 2b is formed in a hollow cylinder shape with the same number of turns and the same winding direction, and is arranged in parallel (side by side) so that the respective axial directions are parallel.
  • the connecting portion 2r is a portion bent in a U shape that connects the winding portions 2a and 2b.
  • the coil 2 may be formed by spirally winding a single winding without a joint.
  • the windings 2a and 2b may be formed by separate windings, and the windings 2a and 2b You may form by joining the edge parts of a coil
  • Each winding part 2a, 2b of this embodiment is formed in a rectangular tube shape.
  • the rectangular cylindrical winding parts 2a and 2b are winding parts having rounded corners whose end face shape is a quadrangle (including a square shape).
  • the winding portions 2a and 2b may be formed in a cylindrical shape.
  • the cylindrical winding portion is a winding portion whose end face shape is a closed curved surface shape (an elliptical shape, a perfect circle shape, a race track shape, etc.).
  • the coil 2 including the winding portions 2a and 2b is a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, magnesium, or an alloy thereof. Can be configured.
  • the winding portions 2a and 2b are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.
  • the magnetic core 3 includes a plurality of columnar inner core pieces 31m,..., A pair of U-shaped outer core pieces 32m, 32m, and a plurality of intervening core pieces. (See FIG. 1).
  • the inner core pieces 31m,... Are magnetic pieces that are entirely disposed within the winding portions 2a, 2b, and the outer core pieces 32m, 32m are magnetic pieces having portions that are disposed outside the winding portions 2a, 2b. That is.
  • the outer core pieces 32m and 32m may have a portion partially disposed in the winding portions 2a and 2b. In this example, the outer core pieces 32m and 32m are outside the winding portions 2a and 2b.
  • the outer core pieces 32m, 32m are arranged so that the U-shaped openings face each other, and the inner core pieces 31m,... Are arranged side by side (in parallel) between the outer core pieces 32m, 32m.
  • FIG. 2 there is a gap between the inner core pieces 31m,..., But the gap resin 31g is filled by filling the gap between the inner core pieces 31m,. ,... (See FIG. 1) are formed.
  • the magnetic core 3 is assembled in an annular shape, and forms a closed magnetic path when the coil 2 is excited.
  • the inner core piece 31m preferably has a shape that matches the shape of the winding portions 2a and 2b.
  • the shape of the inner core piece 31m is a rectangular parallelepiped shape, and the corners thereof are rounded along the corners of the inner peripheral surfaces of the winding portions 2a and 2b.
  • the number of inner core pieces 31m can be selected as appropriate.
  • the pair of outer core pieces 32m, 32m have the same shape and are substantially U-shaped when viewed from above in FIG.
  • the outer core piece 32m is a rectangular parallelepiped outer core base 321 disposed outside the winding portions 2a and 2b and straddling between the winding portions 2a and 2b, and is wound around the outer core base 321.
  • a pair of protrusions 322 disposed in the portions 2a and 2b, respectively.
  • the outer core base portion 321 and the pair of projecting portions 322 and 322 are integrally formed.
  • the end surfaces of the pair of projecting portions 322 and 322 have substantially the same shape and size as the end surface of the inner core piece 31m, and the size and the projecting length have a predetermined magnetic path cross-sectional area corresponding to the coil 2.
  • the pair of protrusions 322 and 322 preferably have a shape that matches the shape of the winding portions 2a and 2b.
  • the corners are substantially at the corners of the inner peripheral surfaces of the winding portions 2a and 2b. Rounded along.
  • the outer core base 321 is integrally formed with a portion (reverse protruding portion) that protrudes on the opposite side to the pair of protruding portions 322 and 322.
  • the reverse projecting portion can be appropriately selected so as to have a predetermined magnetic path cross-sectional area corresponding to the coil 2.
  • the lower surface of the outer core base portion 321 of the U-shaped outer core pieces 32m, 32m protrudes from the lower surface of the inner core piece 31m, and when the coil 2 and the magnetic core 3 are assembled, the lower surface of the outer core base portion 321 is formed. Is flush with the lower surface of the coil 2. That is, the installation surface of the combined body 10 of the coil 2 and the magnetic core 3 is configured by one surface (lower surface) of the coil 2 and one surface of the outer core piece 32m of the magnetic core 3 (lower surface of the outer core base portion 321).
  • the reactor 1 is configured such that the combined body 10 is stably disposed on an installation target (not shown) such as a cooling base, and a part of the magnetic core 3 in addition to the coil 2 is also in contact with the installation target. Increases heat dissipation.
  • both the inner core piece 31m and the outer core piece 32m are compacted bodies.
  • the green compact is typically a raw powder containing a soft magnetic metal powder such as iron or an iron alloy (Fe—Si alloy, Fe—Ni alloy, etc.) and a binder (resin etc.) or a lubricant as appropriate. After being molded, it is obtained by performing a heat treatment for the purpose of removing distortion associated with the molding.
  • a coating powder obtained by subjecting a metal powder to insulation treatment, or a mixed powder obtained by mixing a metal powder and an insulating material the metal powder and the insulating material interposed between the metal particles after forming are substantially used.
  • a compacted green body is obtained. Since this compacting body contains an insulating material, eddy current can be reduced and the loss is low.
  • the gap material 31g is formed by filling a gap formed between the core pieces 31m,..., 32m, 32m with a constituent resin of the resin mold portion 6 described later.
  • the gap material 31g will be described in detail later in the description of the reactor manufacturing method.
  • the interposition member 5 is interposed between the inner surface of the winding portions 2a and 2b and the core portion disposed in the winding portions 2a and 2b of the magnetic core 3, and the coil 2 and the magnetic core 3 It is a member that insulates the gap.
  • a pair of interposition members 5 and 5 are individually arranged with respect to each of the winding parts 2a and 2b.
  • each configuration of the interposition member 5 will be described in detail mainly with reference to FIGS.
  • a pair of interposition member 5 and 5 is the same shape, below, the one interposition member 5 arrange
  • the interposition member 5 has a cylindrical shape and is constituted by a pair of divided interposition members 5A and 5B that are divided in the circumferential direction and sandwich a plurality of core pieces.
  • the interposition member 5 is composed of a pair of divided interposition members 5A and 5B that are divided in the radiation (outer periphery) direction around the axes of the winding portions 2a and 2b.
  • the split interposing members 5A and 5B are straight lines P ⁇ parallel to the upper and lower surfaces of the winding portion 2a (2b) with reference to the axis C of the winding portion 2a (2b). It is divided by P (except for the fitting portion 54).
  • the divided interposing members 5A and 5B are divided by the straight line PP so as to have a divided surface along the axial direction of the winding portion 2a (2b).
  • the straight line PP may be parallel to the left and right surfaces of the winding portion 2a (2b), or may be a straight line such as a diagonal line of the winding portion 2a (2b).
  • the interposition member 5 includes a cylindrical storage portion 51 that sandwiches and stores a portion of the core disposed in the winding portions 2a and 2b of the magnetic core 3 when the pair of split interposition members 5A and 5B are assembled. , 32 m, 32 m, 32 m, 32 m, 32 m, 32 m, 32 m And a flow path 53 to be introduced.
  • the storage part 51 is cylindrical when the pair of split interposed members 5A and 5B are assembled, and is a member capable of storing all of the inner core pieces 31m, ... and the protruding part 322 of the outer core piece 32m. is there.
  • segmentation interposition members 5A and 5B are each comprised by the cross-sectional U-shaped body, and become the cylindrical accommodating part 51 by abutting the opening part of a U-shaped body.
  • the pair of split interposed members 5A and 5B are members having the same shape as shown in FIG. 3, and if the split interposed member 5A is rotated by 180 ° with respect to the split surface, the split interposed member 5B is formed.
  • the storage portions 51 of the divided interposing members 5A and 5B include end strips at both ends, two] strips provided at equal intervals between the end strips, and end portions at both ends on each side surface. Two linear pieces connecting the strips, and one linear piece connecting the end strips at both ends and the two] strips on the bottom surface (upper surface).
  • Each of the end strips has a U-shaped part and a part formed integrally with the U-shaped part and having a leg shorter than the U-shaped part. The length of the leg of this] -shaped part is the same as the length of the leg of the above-mentioned] -shaped strip.
  • the two linear pieces on each side surface are an outer straight piece connecting the U-shaped portions of the end strips, an inner straight piece connecting the] -shaped portion of the end strips and the two] strips. It is.
  • a rectangular piece 51r (see FIG. 3) that connects the two linear pieces is provided at a substantially central portion of the outer straight piece and the inner straight piece.
  • the U-shaped portion of the end strip is a portion where the protruding portion 322 of the outer core piece 32m is disposed.
  • Strips are provided corresponding to the number of inner core pieces 31m,. In this example, two] -shaped strips are provided so that the three inner core pieces 31m,... Are arranged between the end strips.
  • the outer straight piece and the inner straight piece arranged on each side surface are provided corresponding to the flow path 53 described later.
  • the linear pieces arranged on the bottom surface (upper surface) are arranged so that the inner core pieces 31m,... And the protruding portions 322 of the outer core pieces 32m housed in the housing portion 51 are not dropped or displaced.
  • a fitting portion 54 described later is formed on the rectangular piece 51r.
  • the inner surfaces of the storage portions 51 of the divided interposing members 5A and 5B have a shape that matches the shape of each core piece, and the corners of the end strips and the strip-shaped strips are substantially the outer peripheral surfaces of the core pieces. It is rounded along the corner. That is, the accommodating part 51 of the interposing member 5 formed by assembling the divided interposing members 5A and 5B has a shape along the shape of each inner core piece, as shown in the right view of FIG. It becomes a rectangular tube shape with rounded corners.
  • Each core piece is housed in the interposition member 5 when the pair of interposition members 5A and 5B are assembled, a plurality of inner core pieces 31m,... Are placed on one interposition member 5B (5A) and the other division is performed.
  • the interposing member 5A (5B) is placed on the plurality of inner core pieces 31m, and the plurality of inner core pieces 31m are held between the pair of divided interposing members 5A and 5B.
  • a cylindrical storage portion 51 is formed, and insertion holes are formed at both ends (see the right diagram in FIG. 3).
  • the protruding portion 322 of the outer core piece 32m can be inserted and stored through this insertion hole.
  • the thickness between the inner surface and the outer surface of the storage portion 51 is substantially the same as the gap between the outer surface of the inner core piece 31m and the inner surface of the winding portion, and the inner core pieces 31m,. It is mentioned that the interposition member 5 can be inserted and arranged in the winding portion while being sandwiched between the members 5A and 5B.
  • the pair of split interposed members 5A and 5B includes a fitting portion 54 that fits each other.
  • the split interposing members 5A and 5B can be reliably fixed to each other, and when filling the unsolidified constituent resin of the resin mold portion 6 described later, It is possible to reliably prevent misalignment between the core pieces and misalignment between the divided interposing members 5A and 5B.
  • the fitting part 54 is provided on an extension part 54e formed by a rectangular piece 51r extending outward from the opening side of the U-shaped body on one side surface of the split interposing members 5A and 5B, and the extension part 54e. And a fitting protrusion 54b provided on the rectangular piece 51r on the other side surface of the divided interposing members 5A and 5B.
  • the extension portion 54e is a frame-like piece that is substantially the same size as the rectangular piece 51r, and when the pair of split interposition members 5A and 5B are assembled, the extension portion 54e of one split interposition member 5A (5B) , And overlaps the rectangular piece 51r of the other divided interposing member 5B (5A).
  • the extension portion 54e and the rectangular piece 51r are formed so that the total thickness of the two portions 54e and 51r when the two portions 54e and 51r overlap with each other is the thickness between the inner surface and the outer surface of the storage portion 51.
  • the fitting hole 54a is formed over the extending direction of the extending portion 54e, but may be formed only at the tip portion of the extending portion 54e in the extending direction.
  • the fitting protrusion 54b protrudes from the rectangular piece 51r and is formed in a wedge shape having an inclined surface that tapers in the protruding direction and the fitting hole 54a direction.
  • the protrusion length of the fitting protrusion 54b is substantially the same as the thickness of the extension portion 54e.
  • the fitting protrusion 54b is in contact with the periphery of the fitting hole 54a provided in the extension portion 54e (the periphery of the tip portion in the extension direction of the extension portion 54e) when the pair of split interposed members 5A and 5B are assembled. Is provided.
  • the pair of split interposed members 5A and 5B has been described as having a fitting portion 54 that fits each other.
  • the divided interposition members 5A and 5B can be fixed to each other, or the divided interposition members 5A and 5B can be fixed with an adhesive.
  • the guide part 52 protrudes inward of the storage part 51, and secures an interval between the plurality of inner core pieces 31m,... And an interval between the inner core piece 31m and the outer core piece 32m, It is a member for positioning each core piece 31m, ..., 32m.
  • the guide portion 52 is an L-shaped protrusion formed on the] -shaped portion of the end strip and the corners of each] -shaped strip. Therefore, when the plurality of inner core pieces 31m,... Are stored in the storage portion 51, the guide portions 52 are interposed at the four corners of the gap between the inner core pieces 31m,.
  • the guide portion 52 is formed so that the inner core pieces 31m,... And the outer core piece 32m can be arranged at desired positions.
  • the thickness of the guide portion 52 corresponds to the thickness of the gap material 31g (see FIG. 1). Therefore, the inner core pieces 31m,... Can be positioned by simply sandwiching the inner core pieces 31m between the pair of divided interposing members 5A, 5B, and the gap material 31g is provided between the inner core pieces 31m,. A gap corresponding to the thickness of the film can be formed.
  • the end surface of the protrusion part 322 is inserted in the guide part 52 in an end part only by inserting the protrusion part 322 of the outer core piece 32m from the insertion hole formed in both ends by assembling a pair of division
  • the interval between the core pieces 31m, ..., 32m, 32m is more stable and easily secured as the contact area between the inner core piece 31m or the protruding portion 322 and the guide portion 52 increases.
  • the protruding area of the guide portion 52 is increased in order to increase the contact area between the inner core piece 31m or the protruding portion 322 and the guide portion 52, the cross-sectional area of the gap between the core pieces decreases. If it does so, the filling amount of the non-solidified constituent resin of the resin mold part 6 with which it fills between each inner core piece will decrease, and crossing of the gap material 31g (refer FIG. 1) formed with the constituent resin of the resin mold part 6 will be carried out. The area becomes smaller.
  • the filling amount of unsolidified constituent resin in the resin mold part 6 filled between the core pieces decreases, the area where the core pieces are fixed by the resin mold part 6 is reduced, so that the core pieces are firmly fixed. There is a possibility that each core piece may vibrate when the reactor 1 is operated. Therefore, the interval between the inner core pieces 31m,... Can be secured, and the cross-sectional area of the gap material 31g formed by the constituent resin of the resin mold portion 6 is 50% or more of the cross-sectional area of the inner core piece 31m. Furthermore, it is preferable to adjust the protrusion amount of the guide portion 52.
  • the cross-sectional area of the gap material 31g formed by the constituent resin of the resin mold part 6 is 60% or more, further 70% or more, particularly 80% or more of the cross-sectional area of the inner core piece 31m.
  • the guide portion 52 is an L-shaped ridge formed at the corner of each] -shaped strip, but if the core pieces 31m, ..., 32m can be positioned by the guide portion 52,
  • the shape of the guide part 52 is not particularly limited.
  • the guide part 52 may be a U-shaped ridge along the circumferential direction of each] -shaped body.
  • the flow path 53 is a gap between each of the core pieces 31m, ... 32m formed by the guide part 52, when the resin mold part 6 to be described later is molded, the resin resin of the resin mold part 6 that has not been solidified. It is a space that flows in.
  • the flow path 53 includes a groove portion 53 d formed on the inner peripheral surface and the outer peripheral surface of the storage portion 51, and a through hole 53 h formed in the storage portion 51.
  • the molding of the resin mold portion 6 will be described in detail in the description of the manufacturing method of the reactor later.
  • the assembly 10 in which the coil 2, the magnetic core 3, and the interposition member 5 are assembled is placed in a mold, and the resin mold 6 is molded. This is done by filling and solidifying the unsolidified constituent resin of the part 6 in the mold.
  • the groove portion 53d includes a lateral groove portion 53dx formed from both edge portions of the storage portion 51 inward in the axial direction of the winding portion, and a vertical groove portion formed along the circumferential direction of the storage portion 51. 53dy.
  • the lateral groove portion 53dx By providing the lateral groove portion 53dx, the unsolidified constituent resin of the resin mold portion 6 can easily flow into between the core pieces 31m,.
  • the filling of the unsolidified component resin into the mold is usually performed from the upper side of the mold (the upper side of the combined body 10). Therefore, by providing the vertical groove portion 53dy, the unsolidified constituent resin can easily flow more efficiently between the core pieces 31m, ... 32m.
  • the unsolidified constituent resin of the resin mold portion 6 can easily flow into between the core pieces 31m, ... 32m.
  • the unsolidified constituent resin is more likely to flow into between the core pieces 31m,.
  • the through-hole 53h formed so that the gap between the core pieces 31m,... 32m is exposed the unsolidified constituent resin is more likely to flow into between the core pieces 31m,.
  • the unmolded constituent resin of the resin mold part 6 can be disposed between the interposed member 5 and the core pieces 31m,... 32m, or between the interposed member 5 and the coil 2. It is possible to reliably flow in between. Therefore, the contact area between the core pieces 31m,... 32m (magnetic core 3) and the resin mold part 6 and the contact area between the coil 2 and the resin mold part 6 can be increased. Therefore, the bonding strength between the coil 2 and the magnetic core 3 through the resin mold portion 6 can also be improved.
  • the constituent material of the interposition member 5 examples include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6 and nylon 66, polyamide (PA) resin, polybutylene terephthalate (PBT), and the like.
  • PPS polyphenylene sulfide
  • PTFE polytetrafluoroethylene
  • LCP liquid crystal polymer
  • PA polyamide
  • PBT polybutylene terephthalate
  • Resin and thermoplastic resins such as acrylonitrile / butadiene / styrene (ABS) resin can be used.
  • thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used.
  • the interposition member 5 can be easily manufactured by a known molding method such as injection molding of the above resin.
  • the resin mold part 6 is provided so that the outer periphery of the coil 2 and the outer periphery of the magnetic core 3 containing the outer core pieces 32m and 32m may be covered as shown in FIG. Between the two. That is, the resin mold portion 6 integrates the coil 2 and the magnetic core 3 and also ensures insulation between the coil 2 and the magnetic core 3. Further, as shown in the lower diagram of FIG. 1, the constituent resin of the resin mold portion 6 is filled in the gaps between the plurality of core pieces 31 m,... 32 m formed by the guide portion 52 described above. A gap material 31g interposed between the core pieces is formed by the constituent resin of the resin mold portion 6.
  • the resin mold portion 6 is provided so that a part of the upper surface of the coil 2 and the lower surface of the outer core base portion 321 of the coil 2 and the outer core piece 32m are exposed to the outside without being covered.
  • thermoplastic resin such as PPS resin, PTFE resin, LCP, PA resin (nylon 6, nylon 66, etc.), PBT resin, ABS resin or the like
  • thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. Unsaturated polyester is advantageous in that it is difficult to break and is inexpensive.
  • these resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the resin mold portion 6. Further, when the constituent resin of the interposing member 5 and the constituent resin of the resin mold portion 6 are the same resin, the interposition member 5 and the resin mold portion 6 are excellent in integrity.
  • the reactor 1 having the above-described configuration is, for example, a plurality of inner core pieces 31m,... Stored in the storage unit 51 are arranged in the winding unit to form a assembly.
  • the outer core piece 32m to be arranged is assembled to form the combined body 10 ⁇
  • the combined body 10 is disposed in the mold, and the resin mold part 6 is filled and solidified with the unsolidified constituent resin. Can do.
  • a pair of outer core pieces 32m, 32m are assembled to the above-mentioned assembly to form an union 10.
  • the outer core pieces 32m, 32m are inserted into the projecting portions 322, 322 through insertion holes formed at both ends of the cylindrical storage portion 51.
  • the protrusions 322 and 322 are positioned in the winding parts 2a and 2b. It is arranged with.
  • the combined body 10 can be handled as an integral body in which the core pieces 31m,... 32m, 32m are positioned by the interposition member 5.
  • the winding portions 2a and 2b are preferably held in a state of being positioned with respect to the interposing members 5 and 5 by a jig (not shown).
  • a positioning portion for positioning the winding portions 2a and 2b is provided on the interposing members 5 and 5, and the winding portions 2a and 2b are positioned with respect to the interposing members 5 and 5 by this positioning portion. It may be held.
  • the said assembly 10 is arrange
  • the unsolidified constituent resin filled in the mold covers the outer periphery of the coil 2 and the outer periphery of the magnetic core 3, and reaches the gap between the coil 2 and the magnetic core 3.
  • the unsolidified constituent resin flows and fills along the flow path 53 provided in the interposition member 5 up to the gaps formed between the plurality of core pieces 31m,. In this state, by solidifying the constituent resin, the coil 2 and the magnetic core 3 are integrated, and the gap material 31g interposed between the core pieces is formed.
  • the reactor 1 described above can form the gap members 31g between the core pieces 31m, ... 32m, 32m when the resin mold portion 6 is molded, and covers the outer periphery of the coil 2 and the outer periphery of the magnetic core 3 with resin.
  • the coil 2 and the magnetic core 3 can be integrated. Therefore, for example, it is possible to simplify the work of fixing the core piece and the gap material in advance with an adhesive or the like, and individually molding the core piece and the coil with a resin. Excellent.
  • the interposition member 5 is composed of a pair of split interposition members 5A, 5B, the plurality of inner core pieces 31m,... Can be easily accommodated by being sandwiched between the pair of split interposition members 5A, 5B.
  • the inner core pieces 31m Since the plurality of inner core pieces 31m,... are sandwiched and housed between the pair of split interposed members 5A, 5B, the inner core pieces 31m,. It is possible to suppress a positional shift due to a pressure or the like when molding the material by injection molding.
  • the reactor 1 can include a sensor (not shown) that measures the physical quantity of the reactor 1, such as a temperature sensor, a current sensor, a voltage sensor, and a magnetic flux sensor.
  • the sensor can be arranged in a space formed between the two winding portions 2a and 2b.
  • the groove 53d includes a horizontal groove 53dx and a vertical groove 53dy.
  • the lateral groove portion 53dx is formed on both the outer peripheral surface and the inner peripheral surface of the storage portion 51. Further, a large number of the lateral groove portions 53dx are formed on the inner peripheral surface of the U-shaped strip at both ends of the storage portion 51.
  • the lateral groove portion 53dx formed on the outer peripheral surface of the U-shaped strip and the lateral groove portion 53dx formed on the inner peripheral surface of the U-shaped strip are provided at positions that do not overlap when viewed from the inside and outside in a plan view. By doing so, it is possible to more efficiently flow the unsolidified constituent resin of the resin mold portion between the core pieces while ensuring the strength of the storage portion 51.
  • the longitudinal groove portion 53 dy is formed along the circumferential direction of the storage portion 51.
  • the through hole 53h is formed to be smaller than the through hole formed in the interposition member of the first embodiment. Since the through-hole 53h is divided into smaller portions, the interposition member 5 and the resin mold portion are intricately entangled, so that the bonding strength between the interposition member 5 and the resin mold portion can be further improved.
  • a through hole 53h is also formed in the rectangular piece 51r on which the fitting protrusion 54b is formed. Even if the rectangular piece 51r and the extension portion 54e are overlapped, the fitting hole 54a formed in the extension portion 54e is widely formed in the extending direction of the extension portion 54e, so that the rectangular piece 51r is formed.
  • the through-hole 53h is not blocked by the extension 54e. Since the flow path 53 as described above is formed in the storage portion 51, the resin can easily flow in between the core pieces along the flow path 53.
  • the reactor of the present invention includes various on-vehicle converters (typically DC-DC converters) mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles, and converters for air conditioners. It can utilize suitably for the component of a converter and a power converter device.
  • DC-DC converters typically DC-DC converters mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles, and converters for air conditioners. It can utilize suitably for the component of a converter and a power converter device.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulating Of Coils (AREA)

Abstract

L'invention concerne un réacteur dont la productivité est excellente et dans lequel des pièces de noyau peuvent être facilement maintenues à une position prédéfinie. Le réacteur comporte : une bobine qui comprend une partie d'enroulement ; un noyau magnétique qui est formé en combinant les pièces de noyau et un matériau d'entrefer intercalé entre les pièces de noyau et dont une partie est disposée dans la partie d'enroulement ; un organe intercalé cylindrique qui est intercalé entre la surface intérieure de la partie d'enroulement et le noyau magnétique, et qui encadre les pièces de noyau dans une position prédéfinie ; et une partie de moule de résine qui unifie la bobine et le noyau magnétique. L'organe intercalé est composé d'une paire d'organes intercalés divisés dont la direction périphérique est fragmentée et qui encadrent les pièces de noyau, et comporte une partie de guide qui assure un espace entre les pièces de noyau et qui effectue le positionnement des pièces de noyau.
PCT/JP2016/056936 2015-03-11 2016-03-07 Réacteur WO2016143730A1 (fr)

Applications Claiming Priority (2)

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JP2015-048617 2015-03-11
JP2015048617A JP2016171137A (ja) 2015-03-11 2015-03-11 リアクトル

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Cited By (2)

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CN109961941A (zh) * 2017-12-25 2019-07-02 丰田自动车株式会社 电抗器
CN112771633A (zh) * 2018-10-18 2021-05-07 株式会社自动网络技术研究所 电抗器

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6635316B2 (ja) * 2017-02-15 2020-01-22 株式会社オートネットワーク技術研究所 リアクトル
JP6880456B2 (ja) * 2017-10-27 2021-06-02 株式会社オートネットワーク技術研究所 リアクトル
WO2020066631A1 (fr) 2018-09-28 2020-04-02 三菱電機株式会社 Réacteur
DE112021001318T5 (de) * 2020-02-28 2022-12-22 Mitsubishi Electric Corporation Drossel

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Publication number Priority date Publication date Assignee Title
JP2013004531A (ja) * 2011-06-10 2013-01-07 Tamura Seisakusho Co Ltd コイル装置用ボビン
JP2014027087A (ja) * 2012-07-26 2014-02-06 Keihin Corp リアクトル装置

Patent Citations (2)

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Publication number Priority date Publication date Assignee Title
JP2013004531A (ja) * 2011-06-10 2013-01-07 Tamura Seisakusho Co Ltd コイル装置用ボビン
JP2014027087A (ja) * 2012-07-26 2014-02-06 Keihin Corp リアクトル装置

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109961941A (zh) * 2017-12-25 2019-07-02 丰田自动车株式会社 电抗器
CN109961941B (zh) * 2017-12-25 2020-12-11 丰田自动车株式会社 电抗器
CN112771633A (zh) * 2018-10-18 2021-05-07 株式会社自动网络技术研究所 电抗器
CN112771633B (zh) * 2018-10-18 2024-02-13 株式会社自动网络技术研究所 电抗器

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